End cap support for jumbo rolls of material

ABSTRACT

An end cap support for the protruding end of a jumbo roll of paper or other materials (weighing between 2,000 and 4,000 pounds) includes at least one corrugated paper panel bonded to at least one lightweight rigid panel, preferably comprising luaun wood that resists moisture absorption. A very substantial weight reduction is obtained consonant with excellent stacking strength for the end cap support. The luaun panel does not fold over or warp, and all of the materials are biodegradable and hence environmentally friendly.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of application Ser. No.10/173,951 field Jun. 17, 2002, the contents and disclosure of which arehereby incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to very large rolls of material wound on acore and, more particularly, to end cap supports for the rolls ofmaterial in storage or shipping.

2. Description of Related Art

Continuous rolls of material such as tape, paper, plastic film, fabricsand the like are stored and shipped on central cores or spools aroundwhich the material is wound. These rolls may be several feet long andmay weigh at least 2,000 pounds (“jumbo rolls”). The core protrudesbeyond the outer ends of the material, and the protruding core issupported by end caps within a carton, crate, shrink wrap or suitableframe.

At the present time, an end cap is formed from an expanded (foam)polystyrene panel which is glued to a wooden sheet. There are severalproblems with these commercially-available end caps. The glue sometimesfails so that the foam separates from the wood. The core then rests onthe foam which, by itself, is incapable of supporting the weight. Theroll then rests on the shipping carton or crate and is difficult toremove. Sometimes, the heavy roll shifts during transport and may damagethe shipping vehicle or may damage the material on the roll. Thepolystyrene is not biodegradable and disposal introduces environmentalproblems. Further, the wooden sheet must be the same size as thepolyethylene panel for maximum strength and preparation of the end capis relatively costly since there is waste in cutting the wooden sheet tothe required size. Thus, for economy, the wooden sheet is often smallerthan the polystyrene panel and maximum support is not provided.

Additionally, the end caps heretofore used in the prior art arerelatively heavy, thus increasing shipping costs particularly withoverseas shipments.

Another problem encountered in the prior art is warpage of the wooden(or pressed plywood) boards that tend to absorb moisture.

Thus, there is a need for a lightweight, biodegradable and sturdy endcap assembly, one which does not warp nor fail because of moistureabsorption and consequent gluing deficiencies.

BRIEF SUMMARY OF THE INVENTION

Accordingly, it is the primary object of the present invention toprovide an end cap support (or assembly) for jumbo rolls of material,which alleviates the disadvantages and deficiencies of the prior art.

It is another object of the present invention to provide an end capsupport which is lightweight, biodegradable, resistant to moistureabsorption, and utilizes its materials to maximum advantage.

The present invention finds particular utility for use in a jumbo rollof material, wherein the jumbo roll is on a central spool havingrespective ends protruding beyond the jumbo roll, and wherein an end capsupport is provided for each protruding end of the spool, each end capsupport having an opening for receiving the respective protruding end ofthe spool. Within this environment, the present invention comprises animprovement, wherein the end cap support includes at least onecorrugated paper panel bonded to at least one lightweight rigid panel.

In one embodiment of the present invention, the corrugated paper panelincludes a pair of corrugated paper panels bonded on opposite sides ofthe one lightweight rigid panel.

In another embodiment, the corrugated paper panel includes a centralcorrugated paper panel, and the lightweight rigid panel comprises a pairof lightweight rigid panels bonded on opposite sides of the centralcorrugated paper panel. The central corrugated paper panel may includeat least one pair of corrugated paper sheets; alternatively, two pairsof corrugated paper sheets are provided.

Preferably, the pair of lightweight rigid panels includes a pair ofluaun panels that resist moisture absorption

In the preferred embodiment, the corrugated paper panel includessubstantially-tubular channels oriented vertically in use of the end capsupport, thereby substantially assisting in accommodating compressiveloads especially encountered when the jumbo rolls of material arestacked vertically.

In accordance with the teachings of the present invention, the end capsupport is lightweight and biodegradable and comprises a centralcorrugated paper panel including at least one pair of corrugated papersheets. A pair of lightweight rigid panels is bonded to the centralcorrugated paper panel on opposite sides thereof and each of the panelscomprises a luaun panel that resists moisture absorption. The corrugatedpaper panel has substantially-tubular channels oriented vertically inuse of the end cap support, thereby substantially assisting inaccommodating compressive loads especially encountered when the jumborolls of material are stacked vertically.

In accordance with the further teachings of the present invention, theend cap support includes at least one luaun panel and a pair ofcorrugated paper panels bonded to the central lightweight rigid panel onopposite sides thereof.

These and other objects of the present invention will become apparentfrom a reading of the following specification taken in conjunction withthe enclosed drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the prior art.

FIG. 2 is a partial cross-sectional view of the prior art.

FIG. 3 is a cross-sectional view of an end cap support of the prior art.

FIG. 4 is a front view of the end cap support of the present invention.

FIG. 5 is an enlarged cross-sectional view taken across the lines 5-5 ofFIG. 4.

FIG. 6 is an enlarged view of a peeled back corner of FIG. 4.

FIG. 7 is a front view of an alternate embodiment of the end cap supportof the present invention.

FIG. 8 is an enlarged cross-sectional view taken across the lines 8-8 ofFIG. 7.

FIG. 9 is an enlarged view of a peeled back corner of FIG. 8.

FIG. 10 is a cross-sectional view taken across the lines 10-10 of FIG.9.

FIG. 11 is an exploded view of the system of the present invention.

FIG. 12 is a perspective view of the crate of the present invention.

FIG. 13 is an alternate embodiment of the present invention.

FIG. 14 is a cross-section thereof, taken along the lines 14-14 of FIG.13 and enlarged in scale.

FIG. 15 is a further cross-section thereof, taken along the lines 15-15of FIG. 13 and enlarged in scale.

FIG. 16 is a first modification of the embodiment of the invention shownin FIG. 15.

FIG. 17 is a second modification of the embodiment of the inventionshown in FIG. 15.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIGS. 1-3, the prior art has a roll of material 10 wrappedaround a spool (or core) 12. The ends of the spool which protrudeoutwardly from the roll of material are received in an opening 14 ineach of the end cap supports 16. The end cap supports 16 are formed frompolystyrene foam 17 which is glued to a wooden panel 18. The woodenpanel 18 generally has a smaller area than the area of the polystyrenepanel 17. The glue frequently fails and the wood separates from thepolystyrene. The polystyrene by itself does not have the strength tosupport the weight of the roll of material and the polystyrene end capsupport collapses.

The end cap support 20 of the present invention (FIGS. 4-6) is formedfrom a first portion 22 and a second portion 24, each being corrugatedboard. A center portion 26 is sandwiched between the first portion 22and the second portion 24. The center portion is formed from a rigidmaterial. The rigid material may be wood, preferably a heavier plywood,paper board, fiber board, compressed newspaper, plastic or othermaterials known to persons skilled in the art. The plywood may belaminated sheets or may be pressed board. The center portion 26 is gluedto both the first portion 22 and the second portion 24. The firstportion 22 and the second portion 24 preferably are at least two layerslaminated and glued together. The first portion 22 and the secondportion 24 may be formed by folding a single sheet of corrugated boardin half and gluing the two halves together. The corrugated board has aplurality of alternating ribs 28 and channels 30 between outer layers ofheavy paper. The corrugated board in each of the first portion 22 andthe second portion 24 of each end cap support 20 are oriented in avertical manner such that the ribs and channels extend between the topand the bottom of each end cap support 20. The first portion 22, thesecond portion 24 and the center portion 26 are identical in dimensionswith respect to height and width. The thickness of the first portion 22,the second portion 24 and the center portion 26 are not critical and mayvary depending upon the weight of the roll of material 10. Usually, thecenter portion 26 has a thickness of approximately ¼″ and the first andsecond portion each have a thickness of approximately ⅞″. However, thesethicknesses may vary and are not limiting. The height for the end capsupport 20 is greater than the combined diameter of the core 12 and theroll of material 10 wound around the core 12.

Each end cap support 20 has an opening 14 formed therein. Preferably,the opening is circular and is in approximately the center of the endcap support although the opening may be in another location. The opening14 preferably is a through opening extending through the first, secondand center portions. Typically, the opening has a diameter of about 6½″but is not so limited. However, the opening does not necessarily extendthrough all three portions but may be through the first portion, thecenter portion and partially through the third portion. In this manner,the protruding end of the core 12 is received in the opening 14 and issupported by at least the first portion and the center portion. Maximumsupport for the core 12 is provided with a through opening 14 so thatthe protruding end of the core extends completely through the end capsupport 20.

In an alternate embodiment (FIGS. 7-10) the opening 14 is a U-shapedchannel extending from the top of each end cap support 20 toward thecenter of the respective end cap support 20. This embodiment permitseasier installation of the protruding end of the core 12 into theopening 14. Also, since the U-shaped opening is formed from the top ofthe end cap support 20, the vertical orientation of the corrugation isassured to provide maximum strength to the end cap support 20. There isno possibility of having the end cap support 20 disposed on its sidewith respect to the core.

FIGS. 11 and 12 show a storage and shipping container for a jumbo rollof material 10 wound about a core 12. Inside an outer crate, carton orshrink wrapped cover 32, the end cap supports 20 are disposed adjacentto the opposite end walls 34 of the container 32. The ends of the core12 which protrude beyond the roll of material 10 are received in therespective openings 14 on the end cap supports 20. The container 32 isclosed and may be stored or shipped with the contents secure therein.The container may be formed from corrugated board, wood, shrink wrapperor other materials known to persons skilled in the art. The containermay have a bottom portion formed as a pallet to facilitate moving thecontainer by use of a forklift vehicle.

The use of corrugated board, paper board, fiber board, compressednewspaper, plastic or wood in the end cap supports 16 providesbiodegradable materials which meet environmental needs. The polystyrenefoam of the prior art is not biodegradable. The core 12 may be formedfrom spiral wound paper, board, plastic or other material known topersons skilled in the art. Also, the end core supports 16 of thepresent invention are more economical to produce than the end coresupports which are presently used.

With reference to FIGS. 13-15, an end cap support 100 has a centralopening 101 for receiving the respective end of the spool of the jumboroll. As shown, the central opening 101 is circular; however, it will beunderstood that a U-shaped or other opening is feasible consonant withthe teachings of the present invention.

With this in mind, the end cap support 100 includes a central corrugatedpaper panel 102 formed from corrugated paper sheets 103 and 104,respectively. A pair of lightweight rigid panels comprising an innerlightweight rigid panel 105 and an outer lightweight rigid panel 106 arebonded by a suitable adhesive to opposite sides of the centralcorrugated paper panel 102.

As shown, the inner lightweight rigid panel 105 is thicker than theouter lightweight rigid panel 106. However, and with reference to FIG.15, the panels 107 and 108 may be of equal thickness if desired.

More significantly, the lightweight rigid panels 105-108, respectively,are preferably formed from luaun wood which is readily available fromthe Philippines or Indonesia. Luaun wood is strong, lightweight,economical and resists moisture absorption.

With respect to FIG. 17, the central corrugated paper panel 102′includes a pair of panels, each of which includes corrugated papersheets 103 and 104, respectively.

In one example of the present invention, the end cap supports are 32×42inches and 1 inch thick, and each rigid luaun panel is 3.6 mm thick. Ofspecial significance, the end cap supports weigh approximately 12 poundscompared to the prior art commercially-available end cap supports whichweigh approximately 40 pounds. This is a 70% reduction in weight whichtranslates into a substantial savings in shipping costs, especiallyoverseas. The materials are used for their best features, and thefluting or channels of the corrugated paper panels contribute to anexcellent stacking strength for the jumbo rolls which weigh between2,000 and 4,000 pounds. Moreover, the rigid panels don't warp (beingresistant to moisture absorption) nor fold in on itself; and all of thematerials are biodegradable, hence environmental friendly.

Obviously, many modifications may be made without departing from thebasic spirit of the present invention. Accordingly, it will beappreciated by those skilled in the art that within the scope of theappended claims, the invention may be practiced other than has beenspecifically described herein.

1. In a jumbo roll of material, wherein the jumbo roll is on a centralspool having respective ends protruding beyond the jumbo roll, andwherein an end cap support is provided for each protruding end of thespool, each end cap support having an opening for receiving therespective protruding end of the spool, the improvement wherein the endcap support comprises at least one corrugated paper panel bonded to atleast one lightweight rigid panel.
 2. The improvement of claim 1,wherein said at least one corrugated paper panel comprises a pair ofcorrugated paper panels bonded on opposite sides of said at least onelightweight rigid panel.
 3. The improvement of claim 1, wherein said atleast one corrugated paper panel comprises a central corrugated paperpanel, and wherein said at least one lightweight rigid panel comprises apair of lightweight rigid panels bonded on opposite sides of the centralcorrugated paper panel.
 4. The improvement of claim 3, wherein saidcentral corrugated paper panel comprises at least one pair of corrugatedpaper sheets.
 5. The improvement of claim 4, further comprising twopairs of corrugated paper sheets.
 6. The improvement of claim 3, whereinsaid pair of lightweight rigid panels comprises a pair of luaun panelsthat resist moisture absorption.
 7. The improvement of claim 6, whereineach of the luaun panels is of equal thickness.
 8. The improvement ofclaim 6, wherein the luaun panels are of different thickness andcomprise an inner luaun panel which is thicker than an outer luaunpanel.
 9. The improvement of claim 1, wherein said at least onecorrugated paper panel includes substantially-tubular channels orientedvertically in use of the end cap support, thereby substantiallyassisting in accommodating compressive loads especially encountered whenthe jumbo rolls of material are stacked vertically.
 10. In a jumbo rollof material, wherein the jumbo roll is on a central spool havingrespective ends protruding beyond the jumbo roll, and wherein an end capsupport is provided for each protruding end of the spool, each end capsupport having an opening for receiving the respective protruding end ofthe spool, the improvement wherein the end cap support comprises atleast one lightweight rigid panel bonded to a board selected from thegroup comprising corrugated board, paper board, fiber board orcompressed newspaper, such that all of the materials in the end capsupport are biodegradable and hence environmentally friendly, and suchthat a substantial weight reduction is achieved for reduced shippingcosts particularly with overseas shipments.